A Seminar Report on

COAL MINING WASTE REUSE IN CONSTRUCTION INDUSTRY

SUBMITTED BY

MULLA ALISHA JAHANGIR

SEAT NUMBER:- 301C065

T. E. CIVIL

Under the guidance of

Mrs .K.S.PATIL

of

SAVITRIBAI PHULE PUNE UNIVERSITY

DEPARTMENT OD CIVIL ENGINEERING

Sinhgad College of Engineering,
Vadgaon (Bk.), Pune-4

Month October 2023

1
 CERTIFICATE

This is to certify that the Seminar Report entitled(COAL MINING WASTE

REUSE IN CONSTRUCTION INDUSTRY)
MULLA ALISHA JAHANGIR has successfully completed the Seminar Presentation under
the supervision of (Mrs. K.S.PATIL) for the partial fulfillment of Bachelor of CIVIL
ENGINEERING of Savitribai Phule Pune University. This work has not been submitted
elsewhere for the award of any other degree.

Mrs .K. S. PATIL Dr. S.S.SHASTRI

Guide Head of Department

Dr. S.D.LOKHANDE
Examiner Principal

2
 DECLARATION

I hereby declare that the project work entitled “COAL MINING WASTE REUSE IN
CONSTRUCTION INDUSTRY” Submitted to the Sinhgad college of engineering pune,is a
Record of an work done by under the Guidance of “Mrs .K.S.PATIL” Department of Civil
Engineering project work is submitted in the partial fulfillment of the Requirements for the
award of Degree of Bachelor of Engineering.

3
 ABSTRACT

Mother Nature has bestowed India with huge resources of coal, iron ore, bauxite, manganese
and limestone. India has one of the lowest per capita availability of land due to population of
more than 1.3 billion. The transformation from under developed to developed economy
warrants enormous increase in mineral production. This will generate additional huge
quantities of waste. The industry is already facing problems related to land acquisition and
environmental clearances. Sustainable development of Indian mineral industry requires
reprocessing, reuse and recycling of mine waste. To achieve this, economic and innovative
mineral processing methods are required which will result in least damage to ecology and
environment.

4
 INDEX

CHAPTER NO. PARTICULARS PAGE NO.

CHAPTER NO.1 Certificate 1

CHAPTER NO.2 Declaration 2
CHAPTER NO.3 Abstract 3
CHAPTERNO.4 Introduction:- 1) Aim 4
2) Objectives
3) Problem statement

CHAPTER NO.5 Literature Review 11

CHAPTER NO.6 Methodology 12
CHAPTER NO.7 Case study:- 13
CHAPTER NO.8 Concluision 17
CHAPTER NO.9 References. 18

5
 INTRODUCTION

REUSE AND RECYCLING OF COAL MINING WASTE:-

Reuse of mine wastes can be termed as a process that involves the new use or
application of the total mine waste or its part without any reprocessing. Whereas, recycling of
mine wastes is the practice that extracts new valuable resource ingredients, or uses the waste
as feedstock and converts the entire mine waste or its part into a new valuable product or
application with some reprocessing.

Mine waste includes waste rock, mine water and drainage sludge. Reuse and
recycling options of waste rock includes resource of minerals and metals, backfilling material,
landscaping material, aggregate in embankment, road, pavement, foundation and building
construction, asphalt component, feedstock for cement & concrete and as soil additive. Waste
water from mine find use mainly in dust suppression, mineral processing applications, recovery
of metals from waters, drinking water, industrial and agricultural use.

Processing waste mainly includes mill tailings. Various research in use of mill tailings
has confirmed their use as backfill material in underground mines, clay-rich tailings for the
manufacturing of bricks, cement, floor tiles, sanitary ware and porcelains, Mn-rich tailings in
agro-forestry and as coatings, bauxite tailings as sources of alum, Cu-rich tailings as extenders
for paints, Fedrich tailings mixed with fly ash and sewage sludge as lightweight ceramics and
Phosphate-rich tailings for the extraction of phosphoric acid.

Bauxite red mud has a very high alkalinity. It can be used in glass and ceramic industry.
It can also be used to treat AMD and dairy waste water.

1. HOW DO YOU REUSE MINING WASTE:-

Mining waste can be reused in the construction industry in several ways.

1) One of the most common ways is to use mining waste as a substitute for
raw materials in construction materials such as road embankments, sub-
base layers, and backfills.

6
 2) Coal mining industries generate hundreds of millions of tonnes of waste
coal, rock, and cleaning waste stream containing fine coal, coal gangue,
coal sludge, fly-ash, coal mine drainage, and coal bed methane (CBM) that
contaminate the landscape in the mining areas.
3) These wastes can be reused and recycled by technological development
and integrated management for sustainable growth and benefits.

2. WHAT ARE THE METHODS OF COAL PRODUCTION:-

The selection of a mining method depends on factors such as coal seam thickness,
geology, and economics.

The two primary methods of coal extraction are :-underground mining and
surface mining .

1) Underground mining is used when the coal seam is located deep below
the surface, and the overlying rock layers need to be removed to access
the coal.
2) Surface mining, also known as open-cast mining, is used when the coal
seam is located near the surface and can be accessed by removing the
overlying rock layers.
3) The production phase of coal includes extraction, milling, and
processing of coal .
4) The amount of time a mine is in production depends on the amount and
quality of coal in the seam and the profitability of operations .
5) Coal mine site reclamation and protection of the environment start at
the beginning of a project and continue after closure .

7
 HOW WE CAN REUSE WASTE IN MINING INDUSTRY:-

i. One of the most effective ways is to reprocess mine tailings to extract

additional minerals and use the waste for construction purposes in mines .
ii. Another way is to use smart sensor solutions for monitoring environmental
impacts, which can reduce pollution by 5% .
iii. Using cleaner production techniques, environmental control technologies,
waste as raw material, and process re-engineering are other ways to reduce the
waste output of mines .
iv. Additionally, using sustainable equipment can also help reduce waste output .

WHAT ARE THE WASTE PRODUCT IN MINING INDUSTRY:-

i. Mining waste is produced by the extraction and processing of mineral

resources, and through carbon mineralisation, mine waste traps excess
carbon dioxide.
ii. The reprocessing of mine tailings offsets greenhouse gas emissions, while
technologies like automation minimise operational inefficiencies,
maximising production and lowering emissions.
iii. The waste products generated by mining activities can be broadly
classified into three categories: solid wastes, liquid wastes, and gaseous
emissions .

iv. Solid wastes are produced in the form of waste rock, dusts, sludges, and
slags. Liquid wastes are generated in the form of wastewater and
effluents. Gaseous emissions are produced during the extraction and
processing of mineral resources.

WHAT ARE THE USE OF MINE WASTE IN CONSTRUCTION INDUSTRY.

Reuse and recycling options of waste rock includes resource of minerals and
metals, backfilling material, landscaping material, aggregate in embankment,
road, pavement, foundation and building construction, asphalt component,
feedstock for cement & concrete and as soil additive.

8
HOW THEY ARE DISPOSED?

The disposal of mine waste depends on the type of waste produced.

There are two types of mine waste:-

1. Solid mine waste
2. Liquid mine waste
Solid mine waste is typically disposed of in heaps or piles at the source 12. The
overburden, which is the soil and rock removed to access the valuable mineral
deposits, is also considered solid mine waste and is usually displaced at a rate of 5
tons per ton of ore mined .
Liquid mine waste, also known as mine water, is produced in various ways at mining
sites and can vary in levels.

Mining waste is a significant environmental concern, and the construction industry is one of
the sectors that can benefit from its reuse. The reuse of mining waste in construction can
help conserve natural resources and reduce the environmental impact of mining .
Reprocessing, reuse, and recycling of mine waste are essential for sustainable development
of the mineral industry 1.
According to a study, mining waste can be used as a resource for construction in various
ways such as backfilling material, landscaping material, aggregate in embankment, road,
pavement, foundation and building construction, asphalt component, feedstock for cement
& concrete and as soil additive 1. The use of mining wastes in road construction is still under

AIM:-
The aim is to reduce the amount of waste generated by the mining industry and to
minimize the environmental impact of this waste.

OBJECTIVE:-
i. To reduce environmental pollution, conserve natural resources, and create technical
value and economic benefits from waste rock .
ii. The recycling of waste rocks in coal mining for construction materials has been
studied.

9
 iii. To reducing environmental pollution, creating technical value, and economic
benefits from waste rock .

Problem Statement:-

The reuse of coal mining waste in the construction industry is one such
solution that can help reduce the environmental impact of mining and conserve
natural resources .The reuse of coal mining waste in construction can be done
in several ways, including using it as a resource for minerals and metals,
backfilling material, landscaping material, aggregate in embankment, road,
pavement, foundation and building construction, asphalt component,
feedstock for cement & concrete and as soil additive .However, the use of mine
wastes as aggregates in construction is associated with some problems
related to their relatively poor geotechnical properties in addition to their
environmental characteristics .The large amount of coal bottom ash produced
by thermal power plants is one of the primary industrial wastes. Therefore,
using coal bottom ash in the construction industry can save time and reduce
landfill use, cost, and energy

10
 LITERATURE REVIEW

I found a few resources that might be helpful for your literature review on coal mining
waste reuse in the construction industry.

The paper discusses the generation of hundreds of millions of tonnes of waste coal,
rock, and cleaning waste stream containing fine coal, coal gangue, coal sludge, fly-
ash, coal mine drainage, and coal bed methane (CBM) that contaminate the landscape
in the mining areas.

The paper also highlights the reuse and recycling of coal mining waste with zero-
waste approach by technological development and integrated management for
sustainable growth and benefits.

The paper provides an overview of the various types of waste coal and their
environmental impact. It also discusses the current state of research on the reuse and
recycling of coal mining waste in construction materials.

11
 METHODOLOGY

• Coal mining industries generate hundreds of millions of tonnes of waste coal,

rock and cleaning waste stream containing fine coal (a by-product of previous
coal processing operations), coal gangue, coal sludge, fly-ash, coal mine
drainage and coal bed methane (CBM) that contaminate the landscape in the
mining areas .
• The reuse and recycling of coal mining waste with zero-waste approach by
technological development and integrated management for sustainable growth
and benefits is a topic of research .
• The waste material can be reused in the construction of impoundments and haul
roads. Certain tailing waste can be used as granular base/subbase, flowable fill
aggregate or fill, engineered fill or embankment, or asphalt aggregate .
• The potential reuse of coal mine waste rocks (CMWR) as an alternative material
for road construction to conserve the natural resources and sustainable
management of mining waste is also being explored .
• Reuse and recycling options of waste rock include resource of minerals and
metals, backfilling material, landscaping material, aggregate in embankment,
road, pavement, foundation and building construction, asphalt component,
feedstock for cement & concrete and as soil additive.

12
 CASE STUDY

Case studies of Reprocessing, Reuse and Recycling of mining waste.

PROCESSED SAND:-
The waste material from coal mining in India comprises mainly of sandstone, bands
of clay and other metamorphic rocks. The sandstone ranges from coarse grain to fine grain.
The waste rock generated to expose coal is normally backfilled, still a major volume is stacked
over non coal area. As the environmental laws for extracting sand from river bed have become
stringent, sand is in short supply. Western Coalfields Limited (WCL) which is a subsidiary
company of Coal India Limited( CIL), world’s largest coal producing company, has started
crushing and washing of sandstone from its waste dumps and is now major supplier of sand.
This sand is being used for construction of roads and structures. The sand also find use as filling
materials in underground mines of nearby region (6). Other subsidiaries of CIL are also
launching now sandstone processing for supply of sand from waste dumps. A large portion of
land which is presently being occupied by sandstone dumps will be released for better
economic use.

CLAY BAND USE :-

In surface mining method it is possible to mine bands like clay separately and then use
them for making bricks, stemming material and potteries. Clay band at Kampti opencast mine
in WCL is being used for such purposes.

MINE WATER :-
The water from underground mines which was initially discharged into local water
bodies is now treated and used for drinking and industrial purpose. WCL has established a RO
plant of capacity 10,000 liters per hour in Patansaongi village catering to drinking water needs
of around 1,00,000 local populace. Additionally, the plant has a bottling facility through which
“COAL NEER” brand of packaged drinking water is also being launched. Many subsidiaries
of CIL are treating water and are supplying it to local townships and industrial units. Other
subsidiaries of CIL have also started treating underground mine water and are supplying it to
local townships and industries.

13
ECO PARK:-
There are many case studies in the mines of CIL wherein water bodies created from
mining are converted to picnic spots. One such case study which has attracted attention of all
is Eco park at Saoner underground mines lease hold area of WCL. The park utilizes mine water
for gardening, water conservation, boating and amusement purposes. The park showcases
several demonstrable technologies such as Solar electrification of water pump, Rain water
harvesting, micro irrigation, etc. along with a science park and several adventure rides. The
park also has an artificial mine tunnel showcasing different mining job profiles, machinery and
methods used in the coal mines. The annual tourist footfall is more than 50,000. Coal mine
waste Yash Pande and others have carried out study for replacing natural aggregates by thermal
power station coal rejects in granular sub-base and bituminous layers in road construction. The
study has confirmed coal rejects as an alternative to natural aggregate in road construction
works.

IRON ORE TAILINGS(IOT);-

Yelli shetty used iron ore waste from Goa and conducted an experimental study. In the
concrete mix, 40% of coarse aggregates were replaced with iron ore tailings and concrete
blocks were made for 28 days curing. It resulted in the compressive strength of 21.93MPa to
that of granite aggregate of 19.91 MPa. Hence, the increase in the compressive strength was
noticed with iron ore tailings with respect to the conventional coarse aggregate.

IRON ORE WASTE ROCK:-

Gayana B C reported that the workability of all the concrete mixes increased upto 40%,
where natural aggregate in concrete was replacement with iron ore overburden / waste rock
along with upward trend in compressive strength.

FLY ASH :-
Fly ash is produced by coal-fired electric and steam generating plants. It is commonly
used in Portland cement concrete for applications in highway construction, in soil
improvement, as mineral filler in hot mixed asphalt and in grouts for pavement sub sealing. It
is also used in making ash bricks and clinkers for stowing in underground mines.

14
BLAST FURNACE SLAG:-
Blast furnace slag is generated during the melting process in steel making operations. It
is very as a cementitious binder in road construction. It is very commonly used road base
material in France. In areas near to steel plants it is also used as aggregate in road construction.

WASTE DUMP MINING:-

The low grade rejects of past which were dumped are now being mined for metal
extraction. Common example is of manganese ore. The dumps created near Ramtek in Nagpur
district are presently being mined. The grade of the ore is more than 20%.

MINE WASTE FOR PRODUCTION OF DIFFERENT TYPES OF BRICKS :-

It is found from the detailed literature review that there is a lot of scope for utilization
of mine waste/industrial waste in the construction industry in the form of manufacturing of
bricks, paving blocks, tiles etc. Manufacturing of building bricks without burning of solid fuel
is one of the options for reducing the emission of CO2 gas. Srikant etc has given a detailed use
of different type of mine waste for producing different types of bricks .

15
 CONCLUSION

The ore grades and quality have decreased over the decades. Due to the decreasing grades,
more inputs in the form of energy, water, capital and labour are required for the same output
and at the same time larger volumes of waste are generated. Total resource utilization, where
all of the material mined is put to good use, is a challenging concept for researchers and miners.
To achieve near zero waste production circular economy business model has to be employed
for sustainable development of mineral resources. Developed nations should make available
innovative technologies to under developed nations so that total resource utilization is possible.

16
 REFERENCES

1. www.ibef.org, Metals and Mining industry in India

2. Dr. B. K. Pal, etc Problems of mining wastes management in India and its suggestive
measures – case studies,
3. Maedeh Tayebi-Khorami etc, Re-thinking mining waste through an integrative
approach led by circular economy aspirations, www.mdpi.com
4. Bernd G Lottermoser, Recycling, reuse and rehabilitation of mine waste,
www.element magazine.org, Decemmber2011.
5. Larisa CHINDRIS, Valorization of mining waste in the construction industry,
General considerations,
6. Anup Kumar Gupta etc, A review on utilization of coal mine overburden dump waste
as underground mine filling material: a sustainable approach of mining, International
Journal of Mining and Mineral Engineering, 2015 Vol.6
7. Jeroen Spoorena etc, Near-zero-waste processing of low-grade, complex primary
ores and secondary raw materials in Europe: technology development trends, Journal
of Resource, conservation and recycling, May, 2020
8. Yellishetty, M., etc. “Reuse of iron ore mineral wastes in civil engineering
constructions: A case study -resources”, Journal of .Conservation and .Recycling., Vol.
52, 2008
9. B C Gayana etc , A study on suitability of iron ore overburden waste rock for partial
replacement of coarse aggregates in concrete pavements, 14th International Conference
on Concrete Engineering and Technology, IOP publication, 2018.
10. Mishra R R, Inaugural Address of national conference, Geomine 2019, Nagpur
2019.
11. Yash Pandey etc., Utilization of Coal Mixed Waste Aggregates available at Thermal
Power Plants for GSB and Asphalt Mixtures, The 3rd International Conference on
Transportation Geotechnics, Procedia Engineering, 2016.
12. Tara Sen etc, Usage of Industrial Waste Products in Village Road Construction,
International Journal of Environmental Science and Development, Vol. 1, No. 2, June

17